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Thread: the build back

  1. #26
    Join Date
    Jan 2009
    Location
    San Jose, CA USA
    Posts
    1,001
    My Cars
    91 850
    When you're under the car and with your legs crossed like that, you're definitely not hating it. @:- ) Nice progress so far and thumbs up!

  2. #27
    Join Date
    Sep 2017
    Location
    Worcester Ma
    Posts
    52
    My Cars
    1994 840, 2013 X5 335d
    Haha, so true Chris. I planned on cleaning the rest of the engine bay up but the weather had other plans. It went from 65 and sunny to 32 and raining in less than 12 hours. Instead, i cleaned the entire garage. Steady eddy until this runs. More pictures and progress next weekend.
    Last edited by Gregsgroup; 04-16-2018 at 09:25 PM.

  3. #28
    Join Date
    Sep 2017
    Location
    Worcester Ma
    Posts
    52
    My Cars
    1994 840, 2013 X5 335d
    More cleaning and oil pan swap as the replacement engine's pan was dented. Look at the old engine photo compared to the new engine. Night and day. The motor I'm putting in looks brand new inside. Someone changed their oil often. Interestingly, found the same two loose bolts in both motors. I found the smaller bolt (oil pump) and the larger bolt goes to the housing. I used the opportunity to re-torque the oil pump bolts (with lock thread). Tomorrow the new motor gets a new starter, alternator and the oil pump housing swapped. Hopefully soon this engine will be going back in.

    IMG_3522.jpg IMG_3524.jpg IMG_3534.jpg IMG_3537.jpg IMG_3525.jpg
    Last edited by Gregsgroup; 04-21-2018 at 04:00 PM.

  4. #29
    Join Date
    Feb 2010
    Location
    Hampshire UK
    Posts
    6,354
    My Cars
    99 840ci Sport Indv
    Excellent!
    Timm..2007 E64 650i Individual Sport..1999 E31 840ci Individual Sport..ex owner of 2000 E38 740..1999 E38 740i V8 M62..1998 E38 735i V8..1993 E32 730i V8..1988 E28 518i


    My Current 840ci Sport Individual
    My Current 650ci Sport Individual
    My E31 Repair and Information Website
    My E38 Repair and Information Website
    My E63/E64 Repair and Information Website

    Chase - Heroes to a generation

  5. #30
    Join Date
    Jan 2012
    Location
    Upstate South Carolina
    Posts
    267
    My Cars
    1996 840Ci / 2007 B7
    Looks good! (And thanks to your photos, I now know where those pesky heat shields attach that I couldn't remember where they went. Time to put those back in)

  6. #31
    Join Date
    Sep 2017
    Location
    Worcester Ma
    Posts
    52
    My Cars
    1994 840, 2013 X5 335d
    Today was hills and valleys:

    Valleys:
    -New alternator installed including swapping the wiring harness.
    -New seals for the engine motor mount/oil line feed installed
    -New starter prepped with cleaned cover, ready to install once the engine and trans are connected.
    -Bolts removed from fly wheel. (thank you Harbor Freight earthquake gun)
    -New motor mounts installed
    -All radiators, transmission cooler lines, power steering pump, AC compressor and final engine clean pressured washed (used a $79 Ryobi electric pressure, awesome little unit. It beats my gas powered unit for this type of work hands down)
    -I cut the harness in two spots, the single wire 18 gauge wire from the alternator and the 5 wires leading to the starter and oil sensor on the left. I plan on installing quick connectors to make future removal easier.

    Hills:
    -One bolt on the oil pan needs a heli-coil as it spins. I could tap a larger bolt but I like things to be the way they were designed.
    -A while back I purchased a BMW OEM crank sensor. Since its brand new, i wanted to install on this motor. Well, upon removal, a piece of the mount came with the sensor. Now I will either have to tig weld the mount together or use JB weld. The sensor is secure yet, as above, I like when things are they way they should be and will tackle this while the motor is out.
    -The power steering pulley is toast. It looks like someone put a pry bar on the pulley and clipped it in several places. Off to order a new one.

    See you next weekend as we get closer to completion.

    IMG_3538.jpg IMG_3540.jpg IMG_3539.jpg
    Last edited by Gregsgroup; 04-22-2018 at 06:57 PM.

  7. #32
    Join Date
    Sep 2017
    Location
    Worcester Ma
    Posts
    52
    My Cars
    1994 840, 2013 X5 335d
    Closer and closer...

    Accomplished:
    1. Engine and transmission joined and ready to install. Belts dressed and new starter installed.
    2. Crank sensor mount repaired
    3. New transmission mounts installed
    4. Installed new drivers side headlight wiring harness
    5. Purchased a set of staggered M Parallels' with an E38 tire set up. 235/50/18 front and 255/45/18 reads (Toyo Proxys4). Not sure if the fronts can be made to work with a 5mm spacer.

    Still to do pre-engine install:
    1. Install new aux water pump, inline water heater and new HVAC fan
    2. Touch up repaint on frame rails
    3. Repair drivers side headlight adjusters with Max Lumen's kit
    4. Paint transmission cooler and radiator black
    5. Install new power steering hoses in the nose

    Once install is completed:
    1. Replace all suspect rubber hoses
    2. Flush and refill Pentosin CHF11S
    3. Add transmission fluid to replace what came out when the lines where removed
    4. Crank engine a fair amount of time (fuel pump fuse removed) to prime motor.
    5. Repair alternator wire to harness (drivers side) and oil sensor and starter relay wiring (passenger side) with quick connects
    6. Reconnect AC unit hoses (they were empty prior to removing)
    7. Reconnect transmission linkages, electrical plugs and driveshaft (flex joint looks brand new)

    Am I missing anything?

    IMG_3596.jpg IMG_3595.jpg IMG_3598.JPG IMG_3597.jpg
    Last edited by Gregsgroup; 04-29-2018 at 11:43 AM.

  8. #33
    Join Date
    Sep 2017
    Location
    Worcester Ma
    Posts
    52
    My Cars
    1994 840, 2013 X5 335d
    It’s been a while since my last update. It lives. After fighting with exhaust manifolds, the car is completed and runs and drives. I left the covers off of the front to check for any leaks. Also, slightly scratched the right headlight cover, have the SRS code on now as well as a slight hesitation when coasting (rpm drops to idle then comes back with throttle) but that’s it. No leaks, runs cool and it’s oh so clean. Big milestone!!

    97E283A0-2AE1-4B1E-A226-02B442F376A2.jpgF914EED8-4C21-4DBA-BCFF-30E93D5D6E23.jpg 78A07A3A-1437-465B-93E1-F660C79928AE.jpg
    Last edited by Gregsgroup; 06-06-2018 at 02:15 PM.

  9. #34
    tvjake2's Avatar
    tvjake2 is offline SoCalEights - CA BMW CCA Member
    Join Date
    Oct 2012
    Location
    Glendale, CA
    Posts
    1,657
    My Cars
    '97 840Ci, '89 635CSi
    Nicely done! Very methodical. With all this work you've made a reliable beast.

  10. #35
    Join Date
    Feb 2010
    Location
    Hampshire UK
    Posts
    6,354
    My Cars
    99 840ci Sport Indv
    Great news! Check for diagnostic codes for the camshaft sensor - that can drop the revs while you are cruising.....
    Timm..2007 E64 650i Individual Sport..1999 E31 840ci Individual Sport..ex owner of 2000 E38 740..1999 E38 740i V8 M62..1998 E38 735i V8..1993 E32 730i V8..1988 E28 518i


    My Current 840ci Sport Individual
    My Current 650ci Sport Individual
    My E31 Repair and Information Website
    My E38 Repair and Information Website
    My E63/E64 Repair and Information Website

    Chase - Heroes to a generation

  11. #36
    Join Date
    Sep 2017
    Location
    Worcester Ma
    Posts
    52
    My Cars
    1994 840, 2013 X5 335d
    Love vacation. By way of an update, I've put over 400 miles on the 840 post the engine replacement and the car runs very nice. I'm pleased with the performance thus far. So glad I love driving the 840. Makes all of the time and energy well worth the investment. Since the last update:

    Done:
    * Installed a new condenser (Behr) from Rock-auto for short money and recharged the AC. Given its over 100 degrees in MA, it couldn't have come at a better time. Its a pure joy to cruise with the windows up and cool air coming from the vents. Car temps set rock solid slightly under the middle and the aux fan cycled on a few times.

    *Installed staggered M-Parallel rims with Yokohama Advan Sport in 245/40R/18 front and 275/35R/18 rears. Nice balance of handling and quiet road noise. Recommended.

    *Installed an E36 arm rest and CD43 Radio. I sill need to replace my shifter plate once I find a shifter assembly due to the PO breaking the top where the shift knob sits. (thank you Zach "adwebinc")

    *Fixed the driver’s side headlight with three threaded rods and nuts from home depot. Very pleased with this one!

    Still to do:
    *Waiting on a passenger side headlight motor. Once received, I'll most likely rebuild the other headlight and be done with future problems in this area. (Don't worry, there are plenty of other areas which will require my attention). Time-frame: Now

    *I have a few seeping power steering leaks which need to be addressed. I ordered new German stype claps which should do the trick. Time-frame: Now

    *My horn and FTP lights are not working. Its probably something simple (hopefully). Time-frame: Now

    *The headliner is toast. Received a local quote for almost $1,300 to repair, ha! I'm seriously considering a glass moon roof and would love to hear opinions and experiences. Time-frame: Winter

    *Will do both a trans and differential service. Time-frame: Now

    *My gas tank will only fill to half. Will need to chase vacuum lines. Any suggestions? Time-frame: Now

    *The car needs serious paint correction/touch up. Will start looking for a CS I front lower bumper. Time-frame: Winter

    And as it stands now, these items are all that remain to completing "the build back"

    Lastly, you can see a few of our other BMWs, my 13 X5 335d and my oldest son's 08 X3 sport. The other car is our newest purchase, a Pontiac Bonneville GXP for my youngest son. The car only has 57K miles on it; waiting on coil packs for that one. My first car was a 76 Grand Prix that broke its ball joints during my first week of ownership. I guess a Pontiac will always need work. Glad my son will have something nice and dependable to get him through college.

    Happy July 4th holiday everyone, and for all our members or former members of our military, thank you. Thank you for all you have done to protect our country. We wouldn't have our great nation without a strong military and the people who serve.

    car_70318.jpg armrest_70318.jpg radio_70318.jpg
    Last edited by Gregsgroup; 07-03-2018 at 08:35 PM.

  12. #37
    Join Date
    Oct 2008
    Location
    Mt. Dora, Florida
    Posts
    2,385
    My Cars
    Alpina B12 5.7
    Great work, and wonderful father-son time too.

  13. #38
    Join Date
    Feb 2010
    Location
    Hampshire UK
    Posts
    6,354
    My Cars
    99 840ci Sport Indv
    Excellent work!
    Timm..2007 E64 650i Individual Sport..1999 E31 840ci Individual Sport..ex owner of 2000 E38 740..1999 E38 740i V8 M62..1998 E38 735i V8..1993 E32 730i V8..1988 E28 518i


    My Current 840ci Sport Individual
    My Current 650ci Sport Individual
    My E31 Repair and Information Website
    My E38 Repair and Information Website
    My E63/E64 Repair and Information Website

    Chase - Heroes to a generation

  14. #39
    Join Date
    Sep 2017
    Location
    Worcester Ma
    Posts
    52
    My Cars
    1994 840, 2013 X5 335d
    Thanks RogBMW and Tim. Here is something we did once we installed the armrest. Since the cigarette lighter was removed, we added a 3 function power supply to the rear console. This unit has a standard charger, 2 USB chargers and a volt meter in the middle. That volt meter is bright. My son James wired the unit in and added red button to turn the volt meter on and off. Now I can see the status of the charging system when i want to and have enough places to plug in both my phone and GPS
    44AEB9AE-411E-40B9-A655-B10EFD66C31D.jpg 87BD754A-A211-4A33-BA92-750E2C2CAEC1.jpg
    Last edited by Gregsgroup; 07-05-2018 at 01:16 PM.

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